Puncture resistant footbed

ABSTRACT

A footwear system includes a shoe and a footbed. The shoe includes a sole assembly, an upper coupled to the sole assembly, and an interior space that is defined by the sole assembly and the upper. The footbed is movable with respect to the shoe between first and second arrangements. The first arrangement includes the footbed disposed in the interior space and the second arrangement includes the footbed disposed out of the interior space. The footbed includes a flexible layer that has first and second surfaces, and a puncture resistant layer that is coupled to the second surface of the flexible layer. The puncture resistant layer is disposed proximate to the sole assembly in the first arrangement.

CROSS-REFERENCE TO RELATED APPLICATION(S)

The present non-provisional patent application claims the benefit of and priority to U.S. Provisional Patent Application No. 60/946,307 filed Jun. 26, 2007, which is incorporated herein by reference thereto.

TECHNICAL FIELD

The present disclosure relates to footwear and more particularly to puncture resistant footwear.

BACKGROUND

Workers who work in harsh environments often walk on debris on the ground. In many areas, the workers may step on debris such as nails, screws, glass, metal fragments, or other rigid materials may be present that could penetrate through the worker's footwear. Boots have been designed with a metal, puncture resistant layer in the sole to block such debris from penetrating the sole and comprising the area enclosing the worker's foot. Such designs can be uncomfortable, insufficiently flexible, and/or expensive.

SUMMARY

Footbeds according to embodiments of the present disclosure overcome drawbacks and deficiencies of the prior art. A footwear system in accordance with one embodiment of the disclosure includes a and a footbed. The footwear assembly includes a sole assembly, an upper coupled to the sole assembly, and an interior space that is defined by the sole assembly and the upper. The footbed is insertable into and removable from the interior area of the footwear assembly. The footbed includes a flexible support layer that has first and second surfaces, and a puncture resistant layer coupled to the second surface of the flexible layer. In one embodiment, the non-metallic, puncture resistant layer is fixed to the flexible support layer and is disposed between the sole assembly and the flexible support layer so as to provide a puncture resistant barrier between the wearer's foot and the sole assembly.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a partially exploded isometric view of a footwear assembly with a removable, puncture resistant footbed in accordance with an embodiment of the present disclosure.

FIG. 2 is an enlarged cross-sectional view of the puncture resistant footbed of FIG. 1 shown removed from the footwear assembly.

FIG. 3 is an isometric view of a footbed in accordance with another embodiment.

FIG. 4A is a top view of a puncture resistant footbed in accordance with another embodiment of the present disclosure.

FIG. 4B is a left side elevation view of the puncture resistant footbed shown in FIG. 4A.

FIG. 4C is a bottom view of the puncture resistant footbed shown in FIG. 4A.

FIG. 4D is a right side elevation view of the puncture resistant footbed shown in FIG. 4A.

FIG. 4E is a back elevation view of the puncture resistant footbed shown in FIG. 4A.

FIG. 4F is a section view taken along line 4F-4F in FIG. 4C.

FIG. 4G is a section view taken along line 4G-4G in FIG. 4C.

FIG. 4H is a section view taken along line 4H-4H in FIG. 4C.

FIG. 5A is a first perspective view of a puncture resistant footbed in accordance with another embodiment of the present disclosure.

FIG. 5B is a second perspective view of the puncture resistant footbed shown in FIG. 5A.

FIG. 5C is a third perspective view of the puncture resistant footbed shown in FIG. 5A.

FIG. 5D is a fourth perspective view of the puncture resistant footbed shown in FIG. 5A.

FIG. 5E is a fifth perspective view of the puncture resistant footbed shown in FIG. 5A.

DETAILED DESCRIPTION

The present disclosure describes a removable, puncture-resistant insert or footbed for use in footwear. Several specific details of the disclosure are set forth in the following description and in FIGS. 1-5E to provide a thorough understanding of certain embodiments of the disclosure. One skilled in the art, however, will understand that the present disclosure may have additional embodiments, and that other embodiments of the disclosure may be practiced without several of the specific features described below.

FIG. 1 is a partially exploded isometric view of a footwear assembly 100 with a removable footbed 110 in accordance with an embodiment of the present disclosure. The footwear assembly 100 of the illustrated embodiment is a boot 102; however, footwear assemblies according to other embodiments of the present disclosure can include shoes, sandals, and other types of footwear. The boot 102 has a sole assembly 104 and an upper 106. An interior space 108 defined between the sole assembly 104 and the upper 106 is configured to receive a foot of a wearer. The footbed 110 can be disposed in the interior space 108 according to a first arrangement, or can be disposed out of the interior space 108 according to a second arrangement as shown in FIG. 1.

The footbed 110 can be molded in a shape and size to removably fit into the interior space 108 atop the sole assembly 104. In one embodiment, the boot may have a conventional insole that can be removed, and the footbed can be used to replace the insole. In another embodiment, the footbed can be positioned on the boot's insole structure (e.g., if the insole is not removeable). The footbed can be used as an insole that The footbed 110 is shaped and sized relative to the upper and the interior area so that the footbed will be supported by the sole assembly and restrained by the portions of the upper so as to substantially prevent slippage of the footbed laterally or longitudinally relative to the sole assembly. The footbed has a thickness and contoured shape to fit the wearer's foot, but the thickness is controlled so the footbed will not excessively lift the wearer's foot relative to the upper. Accordingly, the contoured footbed can provide a better fit for the wearer's foot in the boot. Contours on the footbed 110 can form an ergonomically shaped support, such as an orthopedic support, for the wearer's foot.

As best seen in FIG. 2, the footbed 110 according to an embodiment of the present disclosure is a removeable, puncture resistant footbed that fits under the wearer's entire foot. The footbed 110 of the illustrated embodiment includes a full-length flexible support layer 112 that can be made from a flexible material, e.g., polyurethane, which can be shaped and sized to ergonomically support the wearer's entire foot. The footbed 110 of the illustrated embodiment can be configured to provide shock pad portions 114 in one or more high impact areas of the footbed, such as in a heel region 116 and a forefoot region 118. Shock pad portions are optional and can be omitted from footbeds according to other embodiments of the present disclosure. In the illustrated embodiment, the shock pad portions 114 are positioned in high impact areas to absorb and dissipate impact loads or other elevated forces, which typically occur during portions of the wearer stride, such as during heel strike, toe-off or other portions of the wearer's stride. According to an embodiment of the present disclosure, the shock pad portions 114 can be integrally formed with the flexible support layer 112. According to other embodiments of the present disclosure, shock pad portions 114 can be independent pad member(s) adhered or otherwise fixed to the top of a flexible layer, or can be independent pad member(s) molded or otherwise disposed in situ within a flexible layer.

According to an embodiment shown in FIG. 3, the flexible support layer 112 has recessed areas formed therein in the heel region 116 and in the forefoot region 118. The shock pad portions 114 are disposed in the recessed areas, such that upper surfaces of the shock pad portions 114 are substantially coplanar with an upper or first surface 112 a of the flexible support layer 112 around the recessed areas. According to embodiments of the present disclosure, the shock pad portions 114 can be molded of a suitably flexible, durable and compressible material, e.g. polyurethane. Configuring the shock pad portions 114 to absorb and dissipate impacts exerted thereon reduces the forces applied to the wearer's foot and/or leg. According to another embodiment of the present disclosure, the upper surface 112 a of the flexible support layer 112 can be contoured to meet the orthopedic needs of a wearer, e.g., in lieu of a separate orthopedic insert.

According to an embodiment of the present disclosure, the footbed 110 can have a top wear layer 120 that covers the upper surface 112 a of the flexible support layer 112 and/or the shock pad portions 114. Accordingly, the top wear layer 120 forms the upper most surface of the footbed 110. According to embodiments of the present disclosure, the top wear layer 120 can include a soft, moisture-wicking cover and/or an antimicrobial cover that can inhibit bacteria growth.

The footbed 110 also has a non-metallic, puncture-resistant layer 130 coupled to a bottom or second surface 112 b of the flexible support layer 112 to provide puncture protection to the full footprint of the footbed 110. The puncture-resistant layer 130 according to embodiments of the present disclosure forms the lower most surface of the footbed 110 and therefore is disposed against the sole assembly 104 of the boot 102. In another embodiment, an additional base layer 122, e.g., a layer of cloth, foam, or other suitable material, can be coupled to the puncture resistant layer 130 so as to form the lower most surface of the footbed 110. As such, the base layer 122 would be disposed against the sole assembly 104 of the boot 102.

The puncture-resistant layer 130 according to an embodiment of the present disclosure is configured to substantially prevent, as an example, a nail, a screw, a spike, a fragment of glass, wood, metal or plastic, or other sharp object, from penetrating through the footbed under the full weight of the wearer and directly contacting the wearer's foot. Accordingly, if a person steps on a sharp object that penetrates through the sole assembly, the puncture-resistant layer 130 prevents the sharp object from penetrating the footbed and puncturing the wearer's foot. Accordingly, a conventional foam shoe insert would not be puncture-resistant so as to prevent penetration therethrough of a sharp object under the weight of a wearer. The puncture-resistant layer 130 can include one or more plies of a puncture-resistant fabric that are adhered, woven or otherwise coupled together. In the illustrated embodiment, the puncture resistant layer 130 is a layer of four-ply material, e.g., “PS4” manufactured by Lenzi Egisto, S.p.A. (Prato, Italy), although other suitable puncture-resistant textiles can be used. A top or first face 130 a of the puncture resistant layer 130 is coupled to the bottom surface 112 b of the flexible support layer 112, and a bottom or second face 130 b of the puncture resistant layer 130 is disposed proximate to the sole assembly 104 of the boot 102.

According to an embodiment of the present disclosure, a method of manufacturing a footbed 110 can include forming the flexible support layer 112 to the desired shape and size (e.g., a shape and sized corresponding to one or more shoe sizes), and placing the flexible support layer in a mold. The puncture resistant layer 130 is also formed to the desired shape and size corresponding to the shape and size of the flexible support layer. The puncture resistant layer 130 can be obtained as a four-ply textile sheet. In one embodiment, the puncture-resistant layer 130 is die-cut to the desired shape and size, although other techniques may be used to provide the puncture resistant layer with the desired shape and size. The puncture-resistant layer 130 is placed in the mold for molding and bonding with the flexible support layer 112.

In the illustrated embodiment, an adhesive, such as a heat activated cement, can be applied to one or both of the puncture resistant layer 130 and the flexible support layer 112 before or after the layers are positioned in the mold. The puncture resistant layer 130 and the flexible support layer 112 are laminated together via the adhesive, e.g., by curing the heat activated cement in a low temperature oven. Other embodiments can use other adhesives that may use, as an example, higher temperatures and/or increased pressures to activate the adhesive or other bonding material, provided that the flexible support layer and the puncture resistant layer 130 can withstand the applied heat and pressure. According to other embodiments, other attachment techniques can be used to join the puncture resistant layer 130 and the flexible support layer 112. According to still other embodiments, the puncture resistant layer 130 and the flexible support layer 112 can be coupled prior to cutting the flexible support layer 112 from the sheet of textile material.

In at least one embodiment, the puncture resistant layer 130 can be molded to have ergonomic contours generally corresponding to contours of a wearer's foot. In one embodiment, the puncture resistant layer 130 can be molded by a contoured surface in the mold as discussed above when the puncture resistant layer 130 is being permanently adhered to the flexible support layer 112. In another embodiment, the flexible support layer 112 may have a contoured shape and sufficient rigidity so that the puncture resistant layer 130 can take on the surface contours of the bottom surface 112 b of the flexible support layer 112 during the coupling and/or molding process. For example, if the bottom surface 112 b has a convex contour, laminating the puncture resistant layer 130 to the flexible support layer 112 can provide a similarly convex contoured puncture resistant layer 130. In yet another embodiment, the puncture resistant layer 130 can be molded to a selected contoured shape to match the contoured shape of a portion of the mold and a contoured bottom surface of the flexible support layer 112. The puncture resistant layer 130 can also conform to more complex contours of the mold and/or the bottom surface 112 b of the flexible support layer. Contouring the puncture resistant layer 130 can facilitate mating engagement when the footbed 110 is fitted into the interior space 108 atop the sole assembly 104.

FIGS. 4A-4H show various views of a footbed 210 according to another embodiment of the present disclosure. The footbed 210 has a top 220 that covers an upper surface 212 a of a flexible layer 212 and/or shock pad portions (not shown). Accordingly, the top 220 forms the upper most surface of the footbed 210. According to embodiments of the present disclosure, the top 220 includes a soft, moisture-wicking cover, e.g., felt, or an antimicrobial cover that can inhibit bacteria growth.

A non-metallic, puncture-resistant layer 230 is coupled to a second, e.g., bottom, surface 212 b of the flexible layer 212 to provide puncture protection to the full footprint of the footbed 210. The puncture-resistant layer 230 according to embodiments of the present disclosure forms the lower most surface of the footbed 210 and therefore would be disposed against the sole assembly 104 of the boot 102.

FIGS. 5A-5E show various perspective views of a puncture resistant footbed 310 in accordance with another embodiment of the present disclosure. The footbed 310 has a flexible layer 312 and a non-metallic, puncture-resistant layer 330 that is coupled to the flexible layer 312 to provide puncture protection to the full footprint of the footbed 310. The puncture-resistant layer 330 according to embodiments of the present disclosure forms the lower most surface of the footbed 310 and therefore would be disposed against the sole assembly 104 of the boot 102.

The capability of footwear to withstand penetration can be evaluated according to a standardized test method, e.g., ASTM Standard F 2412, 2005, “Test Methods for Foot Protection,” ASTM International, West Conshohocken, Pa. A minimum penetration value of 270 pounds-force is promulgated in ASTM Standard F 2413, 2005, “Specification for Performance Requirements for Protective Footwear,” ASTM International, West Conshohocken, Pa. Samples of a footbed 110 according to the present disclosure were tested in accordance with ASTM Standard F 2412-05. A minimum of 368 pounds-force was required to penetrate any of the tested samples. An average force to penetrate any tested sample was a minimum of 396 pounds-force. Therefore, the tested samples of a footbed 110 according to the present disclosure passed ASTM Standard F 2413-05. In fact, test results show the footbed 110 with the puncture resistant layer 130 can withstand approximately 30% more pounds-force than the minimum penetration value promulgated by ASTM Standard F 2413-05.

The puncture-resistant layer 130 provides penetration resistance and structural rigidity to the footbed 110, and the flexible support layer 112 provides heel and arch support for the wearer. At the same time, the combination of the puncture resistant layer 130 and the flexible support layer 112 still allow for smooth flexing of the footbed 110 to accommodate the natural movements of the wearer's foot. As compared to a boot fitted with a conventional steel shank, a footbed 110 according to embodiments of the present disclosure accommodates a more natural movement throughout the wearer's natural gait and is lighter in weight.

The puncture-resistant footbed 110 can be configured to be inserted into a boot or other footwear assembly during initial manufacture or as a retrofit in existing footwear. Accordingly, the puncture resistant footbed 110 can be used to transform virtually any footwear assembly into puncture resistant safety footwear, or to enhance the puncture resistance of conventional footwear.

According to embodiments of the present disclosure, a footwear system can be provided that has a boot or other footwear assembly, at least one puncture resistant footbed, and may also have a conventional footbed. The footbeds can be interchanged by a wearer as desired for an intended use or to refurbish the footwear system. For example, the wearer can configure such a footwear system with less puncture resistance when the boot will be worn in an area or environment without the risk of stepping on a nail, screw or other member that could penetrate through the boot's sole assembly. When enhanced puncture resistance is desirable, the wearer can reconfigure the footwear system by removing the conventional footbed from the boot and inserting a flexible, puncture resistant footbed 110 according to embodiments of the present disclosure. Additionally, the wearer can remove and replace one puncture resistant footbed with another puncture resistant footbed, thereby prolonging the wearable life of the boot or other footwear assembly. According to further embodiments of the present disclosure, a footbed 110 can be manufactured so as to be capable of being removed, cleaned, e.g., washed, and then reinserted in a boot or other footwear assembly.

From the foregoing, it will be appreciated that specific embodiments of the disclosure have been described herein for purposes of illustration, but that various modifications may be made without deviating from the disclosure. Additionally, aspects of the disclosure described in the context of particular embodiments may be combined or eliminated in other embodiments. Furthermore, while advantages associated with certain embodiments of the disclosure have been described in the context of those embodiments, other embodiments may also exhibit such advantages, and not all embodiments need necessarily exhibit such advantages to fall within the scope of the disclosure. Accordingly, the disclosure is not limited except as by the appended claims. 

1. A footbed insertable in an interior space of a footwear assembly configured to receive a wearer's foot and that includes a sole assembly and an upper, the footbed comprising: a flexible support layer removeably insertable in the interior space between the sole assembly and the upper; and a non-metallic, puncture resistant layer fixed to the flexible support layer and movable therewith into a first position disposed between the upper and the sole assembly, the puncture resistant layer being disposed between the sole assembly and the flexible support layer so as to provide a puncture resistant barrier between the wearer's foot and the sole assembly.
 2. The footbed of claim 1 wherein the puncture resistant layer comprises a non-metallic textile adhered to the flexible support layer.
 3. The footbed of claim 1 wherein the puncture resistant layer prevents the object penetrating through the sole assembly with a penetrating force of up to 270 pounds-force from penetrating through the flexible support layer.
 4. The footbed of claim 1 wherein the flexible support layer and the puncture resistant layer in the first arrangement are positioned atop the sole assembly when positioned in the interior area.
 5. The footbed of claim 1 wherein the puncture resistant layer is a conformable layer molded into an ergonomically contoured shape to provide support to the wearer's foot.
 6. The footbed of claim 1 wherein the puncture resistant layer includes a top surface, the flexible support layer includes a bottom surface immediately adjacent to the top surface.
 7. The footbed of claim 1 further comprising a base layer coupled to the puncture resistant layer intermediate the puncture resistant layer and the sole assembly.
 8. The footbed of claim 1 wherein the puncture resistant layer is adhesively coupled to the flexible layer.
 9. The footbed of claim 1, wherein the he flexible support layer comprises an ergonomically contoured top surface to provide support to the wearer's foot.
 10. The footbed of claim 1 wherein the flexible layer comprises a shock pad portion to absorb and dissipate impact forces exerted on the flexible layer.
 11. The footbed of claim 10 wherein the flexible layer includes a recess and the shock pad portion is disposed in the recess.
 12. The footbed of claim 10, wherein a first shock pad portion is disposed at a heel region of the flexible layer, and a second shock pad portion is disposed at a forefoot region of the flexible layer.
 13. A footwear system comprising: a footwear assembly including a sole assembly, an upper coupled to the sole assembly, and an interior space defined by the sole assembly and the upper; and a footbed movable with respect to the footwear assembly between first and second arrangements, the first arrangement including the footbed disposed in the interior space and the second arrangement including the footbed disposed out of the interior space, the footbed including a flexible layer having first and second surfaces, and a non-metallic puncture resistant layer coupled to the second surface of the flexible layer, the puncture resistant layer being disposed proximate to the sole assembly in the first arrangement.
 14. The footwear system of claim 14 wherein the footbed is configured so that an object penetrating through the sole assembly with a penetrating force of up to 270 pounds-force is prevented by the puncture resistant layer from penetrating through the flexible layer.
 15. A method of manufacturing a footbed, the method comprising: forming a flexible material to provide a flexible support layer, the forming includes defining a first surface of the flexible layer with contoured shape to ergonomically support a wearer's foot, the flexible support layer having a first perimeter that defines a shape and size; providing a puncture resistant textile that forms a puncture resistant layer having a second perimeter that substantially matches the shape and size of the first perimeter; and laminating together the flexible layer and the puncture resistant layer in a mold to that the puncture resistant layer is molded into a contoured shape.
 16. The method of claim 15 wherein the laminating comprises adhering a second surface of the flexible layer to the puncture resistant layer.
 17. The method of claim 15, further comprising die cutting a multiple ply puncture resistant textile to form the puncture resistant layer.
 18. The method of claim 15 further comprising covering the first surface of the flexible layer with at least one of a moisture-wicking cover and an antimicrobial cover. 